Aqueous coating compositions for forming anti-grain-puffing coatings on wood substrate, aqueous paints, and articles

ABSTRACT

The present invention relates to aqueous coating compositions for forming an anti-grain-puffing coating, aqueous primers comprising the aqueous coating composition, and articles comprising the anti-grain-puffing coating. In particular, the aqueous coating composition comprises: (a) an aqueous dispersion of polymeric particles, wherein the polymer particles comprise polymer having an anionic hydrophilic group on its molecule chain, and the aqueous dispersion of polymeric particles has a pH of less than 7.0; and (b) an aqueous dispersion of nano-silica.

This application claims the benefit of Chinese application numberCN201711286763.7 filed on Dec. 7, 2017, the entirety of which is herebyincorporated by reference.

TECHNICAL FIELD

The present invention relates to an aqueous coating composition and anaqueous paint formulated therefrom. In particular, the present inventionrelates to an aqueous coating composition for forming ananti-grain-puffing coating on a wood substrate, and an aqueous paintformulated therefrom, comprising a one-part aqueous primer and atwo-part aqueous primer. The present invention also relates to anarticle comprising the anti-grain-puffing coating.

BACKGROUND

Waterborne paints usually contain water instead of organic solvents as adiluent medium, the production, storage and use of which wouldnecessarily reduce the release of organic solvents into the environment,avoid environmental pollution and harm to the construction workers, andalso save resources. Thus, with the increasingly stringent environmentallaws and regulations in various countries in the world, waterbornecoatings have become the main direction for the development of coatingsindustry. The use of waterborne wood coatings may not only meet thesustainable development of energy-saving emission reductionrequirements, but also reduce indoor pollution. Therefore, developmentof high-performance waterborne coatings have become a key point in thecoatings industry.

Wood products, including wood furniture are the most commonly usedproducts in industry and life, which are mainly made of wood substratewith a capillary porous structure on the surface thereof. Beforepainting, in order to achieve a smooth surface, it is usually necessaryto polish the wood substrate first. However, this procedure inevitablyresults in the presence of a large amount of loosely bound wood fiberson the surface of the wood substrate. When the treated substrate isapplied with waterborne wood lacquer, water easily penetrates intocapillaries of the substrate, causing the capillaries to swell, and theloosely bound fibers will protrude over the treated surface to create abumpy coating called a “grain puffing” phenomenon. The existence of thephenomenon will significantly reduce the decorative effect of thecoating.

At present, there are two main methods for reducing or eliminating theissue of “grain puffing” caused by waterborne wood lacquer. The firstmethod is to fill and/or block the capillary on the surface of the woodsubstrate with inorganic particles to reduce the penetration of theaqueous medium, thereby reducing or eliminating the grain puffing of thewood substrate. The second method is to apply a cationic aqueous latexpaint such as XK-350 available from DSM on the surface of the woodsubstrate. The cationic aqueous latex paint may react with an anionicsubstance such as tannin contained in the substrate to form a barrierlayer, and can form a hydrogen bond with a hydroxyl group in the woodsubstrate to prevent moisture from entering the wood substrate, therebyreducing or eliminating the phenomenon of “grain puffing”. However, suchwaterborne latex paint is expensive and has limited application fields.

Thus, there is still a need to an anti-grain puffing coating forimproving performances of the wood substrate.

SUMMARY

In one aspect, the present invention discloses an aqueous coatingcomposition for forming an anti-grain-puffing coating on a woodsubstrate, comprising: (a) an aqueous dispersion of polymeric particles,wherein the polymer particles comprise polymer having an anionichydrophilic group on its molecule chain, and the aqueous dispersion ofpolymeric particles has a pH of less than 7.0; and (b) an aqueousdispersion of nano-silica. Preferably, the aqueous dispersion ofpolymeric particles has a pH of more than 5.0, more preferably has a pHof more than 6.0.

In another aspect, the present invention discloses a one-part aqueousprimer comprising the aqueous coating composition of the presentinvention.

In another aspect, the present invention discloses a two-part aqueousprimer, comprising: (a) the aqueous coating composition of the presentinvention as a film-forming resin; and (b) a blocked isocyanate.

In another aspect, the present invention discloses an articlecomprising: (a) a wood substrate having at least one major surface; (b)an anti-grain-puffing coating directly applied on the major surface ofthe wood substrate, formed from the aqueous coating composition of thepresent invention, or from the one-part aqueous primer or the two-partaqueous primer of the present invention; and (c) a coating applied onthe anti-grain-puffing coating, formed from an aqueous coatingcomposition. Preferably, the article of the present invention has asurface roughness that is at least 30% less than that of an articlecomprising a wood substrate coated with an aqueous dispersion ofpolymeric particles, wherein the polymer particles comprise polymerhaving an anionic hydrophilic group on its molecular chain and having apH greater than 7.0.

In the present invention, the applicant have creatively provided a novelidea for solving the issue of grain puffing when coating a woodsubstrate by applying an aqueous coating composition comprising anaqueous dispersion of polymeric particles, especially an aqueousdispersion of acrylics particles, wherein the polymer particles comprisepolymer having an anionic hydrophilic group on its molecule chain andthe aqueous dispersion of polymeric particles has a pH of less than 7.0(hereinafter referred as an anionic aqueous latex); and an aqueousdispersion of nano-silica to the surface of a wood substrate as ananti-grain-puffing coating. The formation of this anti-grain-puffingcoating significantly reduces or eliminates grain puffing of the woodsubstrate caused by the aqueous coating composition.

In view of the stability of the system, commercially available anionicaqueous latice are generally known to be alkaline, which typically havea pH of above 7.0, preferably about 8.0 or higher. However, theinventors of the present invention have surprisingly found that use ofan anionic aqueous latex having a pH of less than 7.0 in formulating anaqueous coating composition suitable for forming an anti-grain-puffingcoating can produce significantly superior grain puffing resistance,compared to an anionic aqueous latex having a pH of higher than 7.0,which was difficult to anticipate prior to the present invention.

The details of one or more embodiments of the invention will be setforth in description below. The other features, objectives, andadvantages of the invention will become apparent.

Definition

As used herein, “a”, “an”, “the”, “at least one”, and “one or more” areused interchangeably, unless indicated otherwise. Thus, for example, acoating composition that comprises “an” additive can be interpreted tomean that the coating composition includes “one or more” additives.

Throughout the present invention, where compositions are described ashaving, including, or comprising specific components or fractions, orwhere processes are described as having, including, or comprisingspecific process steps, it is contemplated that the compositions orprocesses as disclosed herein may further comprise other components orfractions or steps, whether or not specifically mentioned in thisdisclosure, as long as such components or steps do not affect the basicand novel characteristics of the invention, but it is also contemplatedthat the compositions or processes may consist essentially of, orconsist of, the recited components or steps.

For the sake of brevity, only certain ranges are explicitly disclosedherein. However, ranges from any lower limit may be combined with anyupper limit to recite a range not explicitly recited, ranges from anylower limit may be combined with any other lower limit to recite a rangenot explicitly recited, and in the same way, ranges from any upper limitmay be combined with any other upper limit to recite a range notexplicitly recited. Additionally, within a range includes every point orindividual value between its end points even though not explicitlyrecited. Thus, every point or individual value may serve as its ownlower or upper limit combined with any other point or individual valueor any other lower or upper limit, to recite a range not explicitlyrecited.

When used in the context of wood substrates, the term “major surface” isa surface defined by the lengthwise and widthwise dimensions of the woodsubstrates for providing the decoration.

Herein, the term “surface roughness” is a parameter used for measuringthe extent to which a wood substrate is penetrated by an aqueous coatingcomposition. The smaller the surface roughness indicates that the woodsubstrate exhibits lower grain puffing.

The term “on” when used in the context of “a coating applied on ananti-grain-puffing coating, formed from an aqueous coating composition”includes the coating being applied directly or indirectly on theanti-grain-puffing coating. In some embodiments of the invention, thecoating formed from the aqueous coating composition is applied directlyto the anti-grain-puffing coating and is in direct contact with theanti-grain-puffing coating. In some embodiments of the invention, one ormore layers of colorant may be present between the coating formed fromthe aqueous coating composition and the anti-grain-puffing coating so asto achieve the desired color.

The term “comprises” and variations thereof do not have a limitingmeaning where these terms appear in the description and claims.

The terms “preferred” and “preferably” refer to embodiments of theinvention that may afford certain benefits, under certain circumstances.However, other embodiments may also be preferred, under the same orother circumstances. Furthermore, the recitation of one or morepreferred embodiments does not imply that other embodiments are notuseful, and is not intended to exclude other embodiments from the scopeof the invention.

DRAWINGS

FIG. 1 shows the surface morphology of the sample which is formed byusing the present aqueous coating composition as an anti-grain-puffingcoating and applying an aqueous coating composition on theanti-grain-puffing coating, in which Examples 1-1 to 1-4 represent theresults obtained by sampling in different areas of the sample.

FIG. 2 shows the surface morphology of the comparative sample which isformed by using an anionic aqueous latex having a pH of more than 7.0 asan anti-grain-puffing coating and applying an aqueous coatingcomposition on the anti-grain-puffing coating, in which Examples 1-1 to1-4 represent the results obtained by sampling in different areas of thecomparative sample.

DETAILED DESCRIPTION

In one aspect, the present invention discloses an aqueous coatingcomposition for forming an anti-grain-puffing coating on a woodsubstrate, comprising (a) an aqueous dispersion of polymeric particles,wherein the polymer particles comprise polymer having an anionichydrophilic group on its molecule chain and the aqueous dispersion ofpolymeric particles has a pH of less than 7.0; and (b) an aqueousdispersion of nano-silica.

As used herein, the term “aqueous dispersion of polymeric particles”refers to a stable dispersion of synthetic resin (i.e., polymer) in theform of particulates in an aqueous liquid medium, optionally with theaid of suitable dispersing aids such as surfactants. Thus, when used inthe content of polymer, the terms “aqueous dispersion of polymericparticles” and “aqueous latex” may be used interchangeably unlessotherwise stated. Methods of preparing aqueous dispersions of thepolymeric particles of the present invention are known in the art whichcan be prepared, for example, using emulsion polymerization processesknown to those skilled in the art. The emulsion polymerizationpreparation process generally comprises the steps of dispersingpolymerizable monomers in water into an emulsion under the action of asuitable emulsifier and/or a dispersing stabilizer by means of stirring,and for example initiating polymerization of the monomers by adding aninitiator. In the present invention, the polymeric particles may bemodified by, for example, modification of an organic functional groupincluding but not limited to a carboxyl group, a hydroxyl group, anamino group, an isocyanate group, a sulfonic acid group, etc. to obtainan aqueous latex with desired properties, for example dispersingproperties. Thus, in the present invention, the term “aqueous latex”includes not only a dispersion of unmodified polymeric particles in anaqueous medium, but also a dispersion of organic functionalgroups-modified polymeric particles in an aqueous medium.

In the aqueous coating composition according to the invention, theaqueous dispersion of polymeric particles used has a pH of less than7.0. Preferably, the aqueous dispersion of polymeric particles has a pHgreater than 5.0, more preferably greater than 6.0. In a preferredembodiment of the invention, the aqueous dispersion of polymericparticles has a pH in the range of 6.2-6.8.

In the aqueous coating composition according to the present invention,the polymer contained in the polymeric particles of the aqueousdispersion has one or more anionic hydrophilic groups on the molecularchain, and thus the aqueous dispersion of such polymeric particles isalso known as an anionic aqueous latex in the present invention. In someembodiments of the invention, the anionic hydrophilic group can be inthe form of an acid, such as a carboxylic acid group, a sulfonic acidgroup, a phosphate group, a phosphonic acid group, a phosphinic acidgroup, and the like. Additionally, a portion of the anionic hydrophilicgroup of the anionic aqueous latex may be in the form of an acid salt,such as a neutralized acid or anhydride, for achieving a suitablestability. Examples of suitable anionic hydrophilic groups in the formof acid salts include carboxylate (—CO₂ ⁻), sulfate, phosphate,sulfonate, phosphite, phosphonate, and combinations thereof. In apreferred embodiment of the present invention, the anionic hydrophilicgroup comprises not only an anionic hydrophilic group in the form of anacid but also an anionic hydrophilic group in the form of an acid salt.

The inventors of the present invention have surprisingly found that useof an anionic aqueous latex having a pH of less than 7.0 in formulatingan aqueous coating composition suitable for forming ananti-grain-puffing coating may produce significantly superior grainpuffing resistance, compared to an anionic aqueous latex having a pH ofhigher than 7.0.

In the aqueous coating composition according to the present invention,the aqueous dispersion of the polymeric particles used may also have acertain hydroxyl value, and thus the aqueous coating compositionaccording to the present invention may be combined with a hydroxylreactive curing agent to form a two parts system. In one embodiment ofthe present invention, the aqueous dispersion of polymeric particles hasa hydroxyl number of from 0 to 100 mg KOH/g, preferably a hydroxylnumber of from 20 to 80 mg KOH/g.

In the aqueous coating composition according to the invention, theaqueous dispersion of polymeric particles comprises polymeric particleshaving a certain particle size. Preferably, the polymeric particles havesuch a small particle size that they can block or fill into thecapillaries of the wood substrate, thereby reducing or inhibiting theintake of moisture. The size of the polymeric particles can be measuredby a Z-average particle size known in the art, which refers to theparticle size as determined by dynamic light scattering, for example,using a Marvlen Zetasizer 3000HS microparticle size analyzer. In oneembodiment of the invention, the aqueous dispersion of polymericparticles comprises polymer particles having a particle size of lessthan 100 nm, preferably comprising polymer particles having a particlesize of less than 80 nm. Moreover, the polymeric particles have aparticle size greater than 20 nm, more preferably greater than 30 nm. Ina specific embodiment of the invention, the polymeric particles have aparticle size between 40 and 70 nm. It has been observed that theaqueous dispersion comprising polymeric particles having the aboveparticle size range allows the polymeric particles to readily penetrateinto the texture and block the pores of the wood substrate, therebyreducing the grain puffing of the wood substrate. If the particle sizeis too small, the polymer cannot effectively block the texture and/orpores of the wood substrate, and if the particle size is too large, itcannot enter the pores of the wood substrate, and thus cannot preventgrain puffing.

According to the present invention, the aqueous dispersion of polymericparticles can be an aqueous dispersion of any type of polymericparticles, including aqueous dispersions of silicones, aqueousdispersions of styrene-acrylates, aqueous dispersions of acrylates,aqueous dispersion of organic silicone modified acrylates, aqueousdispersion of vinyl acetate, aqueous dispersion of vinylacetate-acrylates, aqueous dispersion of vinyl acetate ethylene, aqueousdispersion of ethylene vinyl acetate, aqueous dispersion of vinylacetate-acrylate-ester of versatic acid, or a combination thereof. In apreferred embodiment of the invention, the aqueous dispersion ofpolymeric particles is an aqueous dispersion of acrylates.

As noted above, the anionic aqueous latexes having a pH of less than 7.0can be prepared by suitable emulsion polymerization methods well knownto those skilled in the art. Alternatively, it may be commerciallyavailable, such as DSM latex XK-102.

Preferably, the aqueous coating composition of the present inventioncomprises from about 70% to about 90% by weight of the above aqueouslatex based on the total weight of the aqueous coating composition. Morepreferably, the amount of the aqueous latex may be from about 71% byweight, about 72% by weight, about 75% by weight to about 90% by weight,about 88% by weight, about 85% by weight based on the total weight ofthe aqueous coating composition. Furthermore, if additional water isadded during the preparation of the aqueous coating composition, theamount of additional water, together with the water present in theaqueous latex of the acrylics polymer, should be included in the totalweight of the aqueous latex. In the present invention, the anionicaqueous latex has a solid content of 30-50%.

The aqueous coating composition according to the present inventionfurther comprises an aqueous dispersion of nano-silica. When used hereinin the content of “aqueous dispersion of nano-silica”, “nano-silica”refers to nano-sized silica that is substantially insoluble in theaqueous dispersing medium at the temperature of interest but isdispersed therein in a finely dispersed form. The nano-silica may be asolid having a nano-sized spherical, fibrous, sheet or other regular orirregular shape.

According to the invention, the nano-silica has a particle size of from5 to 100 nm, preferably of less than 80 nm.

The inventors of the present invention have found that the aqueousdispersion of nano-silica can be a useful aider to the anionic aqueouslatex having a pH of less than 7.0. Upon forming an anti-grain-puffingcoating on the wooden substrate, the nano-silica in the aqueous coatingcomposition is filled into the capillary of the wood substrate,effectively sealing the capillary of the wood, thereby further improvingthe anti-grain-puffing effect of the aqueous coating composition.

Preferably, the aqueous coating composition of the present inventioncomprises from about 0.1 to about 10% by weight, based on the totalweight of the aqueous coating composition, of the above-describedaqueous dispersion of nanosilica. More preferably, the amount of theaqueous dispersion of nanosilica may be from about 1% by weight, about2% by weight and about 5% by weight to about 10% by weight, and about 9%by weight and about 8% by weight based on the total weight of theaqueous coating composition.

The present aqueous coating composition may optionally includeadditional additives for an aqueous coating composition which do notadversely affect the coating composition or a resultant coating obtainedtherefrom. Suitable additives include, for example, those that improvethe processability or manufacturability of the composition, enhancecomposition aesthetics, or improve a particular functional property orcharacteristic of the coating composition or the cured compositionresulting therefrom, such as adhesion to a substrate. Additives that maybe included are, for example, carriers, emulsifiers, pigments,anti-migration aids, anti-microbials, extenders, lubricants, wettingagents, biocides, plasticizers, antifoaming agents, colorants, waxes,anti-oxidants, anticorrosion agents, flow control agents, thixotropicagents, dispersants, adhesion promoters, UV stabilizers, a thickener, adefoamer, a pH adjuster, a silane coupling agent, a high boiling filmforming agent, or combinations thereof. Each optional ingredient can beincluded in a sufficient amount to serve its intended purpose, butpreferably not in such an amount to adversely affect a coatingcomposition or a cured coating resulting therefrom.

In an embodiment according to the present invention, the aqueous coatingcomposition of the present invention comprises 70 to 90% by weight ofthe aqueous dispersion of polymeric particles, 0.1 to 10 wt % % of theaqueous dispersion of nanosilica; and 0-29.9 wt % of additionaladditives relative to the total weight of the aqueous coatingcomposition.

The inventors of the present invention have also surprisingly found thatthe aqueous coating composition of the present invention has anexcellent sealing effect. After further applying an aqueous coatingcomposition to the anti-grain-puffing coating formed from the aqueouscoating composition of the present invention, the resulting article hasan acceptable surface roughness, which is significantly lower than thatof the article with an anionic aqueous latex having a pH greater than7.0. In one embodiment of the present invention, the article prepared bysealing the wood substrate with the present aqueous coating compositionfollowed by applying an aqueous coating composition has a surfaceroughness that is 30% or more, preferably 40% or more, more preferably50% or more less than the article prepared by sealing the wood substratewith an anionic aqueous latex having pH more than 7.0 followed byapplying an aqueous coating composition

In the present invention, the aqueous coating composition can be used asit is, which is applied to a substrate to form a coating, preferably asa primer layer in direct contact with the substrate. Accordingly, thepresent invention is also directed to a one-part aqueous primercomprising the aqueous coating composition of the present invention.

In the present invention, the aqueous coating composition may also becombined with a hydroxyl reactive curing agent to form a two-partscoating system that is applied to a substrate to form a coating,preferably as a primer layer in direct contact with the substrate.Accordingly, the present invention in another aspect discloses atwo-parts aqueous primer comprising (a) the aqueous coating compositionof the present invention as a film-forming resin component; and (b) ablocked polyisocyanate curing agent.

According to the invention, the blocked isocyanate means an isocyanatethat is blocked by an active hydrogen-containing material, including ablocked aliphatic polyisocyanate, a blocked cycloaliphaticpolyisocyanate, a blocked aromatic polyisocyanate or combinationsthereof.

Non-limiting examples of blocked isocyanates include blocked aliphaticand/or cycloaliphatic polyisocyanates such as HDI (hexamethylenediisocyanate), IPDI (isophorone diisocyanate), TMXDI(di[isocyanatocyclohexyl]methane), HINDI (tetramethylene-m-xylylenediisocyanate), TMI (isopropenyldimethylbenzyl isocyanate) and dimers ortrimers thereof; and blocked aromatic polyisocyanates such asp-phenylene diisocyanate, toluene-2,4-diisocyanate,naphthalene-1,4-diisocyanate, biphenyl-4,4′-diisocyanate,benzene-1,2,4-triisocyanate, xylene-1,4-diisocyanate,xylene-1,3-diisocyanate, diphenylmethane diisocyanate. Suitable blockingagents include, for example, phenols such as phenol, m-nitrophenol,p-chlorophenol, catechol; malonates such as diethyl malonate,acetylacetone, ethyl acetoacetate; other blocking agents, such asn-butanone oxime, ε-caprolactam and secondary amines.

The blocked isocyanate may have a suitable molecular weight as needed.In some embodiments, the blocked isocyanate that can be used has an Mnof at least about 300, more preferably at least about 650, and even morepreferably at least about 1000.

The blocked isocyanates are commercially available, and non-limitingexamples of suitable commercially available blocked isocyanates includeVESTANAT B 1358 A, VESTANAT EP B 1186 A, VESTANA EP B 1299 SV (fromDegussa Corp., Marl, Germany); and DESMODUR VPLS 2078 and DESMODURBLL3175SN (available from Bayer AG, Leverkusen, Germany).

Preferably, in the two-parts aqueous primer of the present invention,the amount of the blocked polyisocyanate curing agent is generallydependent upon the film forming resin component and can be determinedempirically.

In another aspect, the present invention discloses an article,comprising (a) a wood substrate having at least one major surface; (b)an anti-grain-puffing coating directly applied on the major surface ofthe wood substrate, formed from the aqueous coating composition of thepresent invention, or from the one part aqueous primer or the two partsaqueous primer of the present invention; and (c) a coating applied onthe anti-grain-puffing coating, formed from an aqueous coatingcomposition.

As the wood substrate used to make the article of the present invention,any suitable wood substrate known in the art can be used. According tothe invention, the wood substrate has at least one, preferably two,major surfaces that are opposite one another. As used herein, “majorsurface” is a surface defined by the lengthwise and widthwise dimensionsof the wood substrate for providing the decoration.

Preferably, the major surface of the wood substrate may contain polargroups such as hydroxyl groups, amino groups, mercapto groups, etc., sothat the anionic aqueous latex having pH of less than 7.0 contained inthe aqueous coating composition according to the present invention caneasily wet the major surface when it is applied thereto, thereby forminga coating. Methods for obtaining a wood substrate having a major surfacewith hydroxyl groups are known in the art. Specifically, the hydroxylgroup may be introduced on the surface of the wood substrate byperforming surface treatment on the major surface of the wood substrate,for example, by corona treatment.

According to the present invention, the wood substrate comprises a softwood substrate, a hard wood substrate or a combination thereof. As anexample of a soft wood substrate, pine, cedar or fir can be used. As anexample of a hard wood substrate, ashtree, white ash, basswood, elm,maple, birch, alder, beech, oak, rubber wood, cherry, walnut, orrosewood can be used. In one embodiment of the present invention, solidoak board is used as the wood substrate.

According to the invention, the aqueous coating composition can beapplied by customary application processes known to a person skilled inthe art. The application processes comprise dip coating, spin coating,spray coating, curtain coating, brush coating, roll coating, and othercoating methods known in the art. In one embodiment of the presentinvention, application is carried out by spray coating.

In the article according to the present invention, one or more coatingsformed from an aqueous coating composition may be applied to the surfaceof the anti-grain-puffing coating. According to the present invention,the coating may comprise a primer coating, an intermediate coating, atopcoat coating, or a combination thereof. The coating can be applieddirectly to the anti-grain-puffing coating and is in contact with theanti-grain-puffing coating. In some embodiments of the invention, one ormore colorant layers may be present between the coating formed from theaqueous coating composition and the anti-grain-puffing coating so as toachieve the desired color.

According to the present invention, two or more coatings formed from theaqueous coating composition may be applied to the anti-grain-puffingcoating, preferably three or more coatings formed from the aqueouscoating composition, and more preferably, 4 or more coatings formed fromthe aqueous coating composition without affecting the barrier effect ofthe anti-grain-puffing coating.

According to the present invention, the aqueous coating composition maybe any aqueous coating composition known to those skilled in the artthat is suitable for coating wood substrates. In one embodiment of theinvention, the aqueous coating composition is a water-soluble coating,preferably comprising polyvinyl alcohol as the film-forming resin. Inanother embodiment of the present invention, the aqueous coatingcomposition is a water-dispersible coating, preferably comprising afilm-forming resin including, but not limited to, an aqueous dispersionof organic silicone, an aqueous dispersion of styrene-acrylate, anaqueous dispersion of acrylates, an aqueous dispersion of organicsilicone-modified acrylate, an aqueous dispersion of vinyl acetate, anaqueous dispersion of vinyl acetate-acrylate, an aqueous dispersion ofvinyl acetate-ethylene, an aqueous dispersion of vinylacetate-acrylate-esters of versatic acid, an aqueous dispersion ofpolyurethane, an aqueous dispersion of acrylate-polyurethane or anycombination thereof.

The aqueous coating composition of the present invention may furthercomprise one or more fillers. As used herein, the term, “filler”, isintended to refer to any coating volume extender, either organic orinorganic, in the form of e.g., particles or powders. There is noparticular limitation on the shape of particles, and the filler may haveany suitable shape. The particle size of the filler may vary over abroad range, e.g., from about 10 nanometers to about 50 micrometers. Inaddition to functioning as a coating volume extender, some fillers mayimpart one or more desired properties to the composition and/or coatingresulted from the composition. For example, some fillers may impartdesired color to the composition and hence the coating resulted from thecomposition, and in this case such fillers may be also referred to as“pigment”. Some fillers may improve chemical and/or physical properties,in particular mechanical properties of the coating resulted from thecomposition, and in this case they may also be referred to as “enforcingadditive”.

The present aqueous coating composition may optionally includeadditional additives for an aqueous coating composition which do notadversely affect the coating composition or a resultant coating obtainedtherefrom. Suitable additives include, for example, those that improvethe processability or manufacturability of the composition, enhancecomposition aesthetics, or improve a particular functional property orcharacteristic of the coating composition or the cured compositionresulting therefrom, such as adhesion to a substrate. Additives that maybe included are, for example, carriers, emulsifiers, pigments,anti-migration aids, anti-microbials, extenders, lubricants, wettingagents, biocides, plasticizers, antifoaming agents, colorants, waxes,anti-oxidants, anticorrosion agents, flow control agents, thixotropicagents, dispersants, adhesion promoters, UV stabilizers, a thickener, adefoamer, a pH adjuster, a silane coupling agent, a high boiling filmforming agent, or combinations thereof. Each optional ingredient can beincluded in a sufficient amount to serve its intended purpose, butpreferably not in such an amount to adversely affect a coatingcomposition or a cured coating resulting therefrom.

According to the present invention, the preparation of the aqueouscoating composition can be accomplished using any suitable method knownto one of ordinary skill in the art. For example, the aqueous coatingcomposition can be made by adding all of the components to a containerand then stirring the resulting mixture until homogeneous.Alternatively, the aqueous coating composition can be made by firstmixing some of the components and then adding the rest of the othercomponents to form a homogeneous mixture. Alternatively, any suitablecommercially available aqueous coating composition may be used, such asan acrylic aqueous sealant and/or varnish from Valspar (China), such as470C4015K, 481C54086K.

According to the present invention, the aqueous coating composition canbe applied by conventional application processes known to those skilledin the art. The application processes include dip coating, spin coating,spray coating, curtain coating, brush coating, roll coating, and otherapplication processes known in the art. According to the presentinvention, a wet on dry application process is applied. Typically, anaqueous liquid medium comprising water and any co-solvent is removed bynatural or accelerated (heat) drying to form a coating.

According to the present invention, the article can be prepared, forexample, by (1) providing a milled wooden substrate; (2) applying anaqueous coating composition of the present invention to the woodsubstrate using a spray coating process, thereby forming ananti-grain-puffing coating; and (3) sequentially applying one or moredesired coatings formed from the aqueous coating composition to theanti-grain-puffing coating using a wet-on-dry coating process.Optionally, the colorant may be coated on the anti-grain-puffing coatingprior to step (3) so as to provide the wood substrate with the desiredcolor.

According to the present invention, the articles thus obtained may beused for applications including, but not limited to, household furnituresuch as tables, chairs, cabinets and the like; bedroom and bathroomfurniture; office furniture; custom furniture such as school andchildren's furniture, hospital furniture, restaurant and hotelfurniture, kitchen cabinets and furniture; interior design panels;indoor and outdoor windows and doors; indoor and outdoor window and doorframes; outdoor and indoor wall panels and wood floors.

The following examples describe the present invention in more detail,which are for illustrative purposes only, since various modificationsand changes will be apparent to those skilled in the art from the scopeof the present invention. Unless otherwise indicated, all parts,percentages, and ratios reported in the following examples are on aweight basis and all reagents used in the examples are commerciallyavailable and may be used without further treatment.

EXAMPLES

Treatment of Wood Substrates

Oak wood boards commercial available from the timber market were dried.A sample of size 15 cm*15 cm*1.5 cm was taken from the dried board andconditioned at a temperature of 25° C. and a relative humidity (RH) of60% with an air flow rate of 1.8 m/s to constant, where the equilibriummoisture content of the sample was 11%. A strip sander was used topolish the sample by using a sandpaper purchased from 3MT Utility ClothSheet 240 and then the polished sample was cleaned with a pressure gun.

COMPARATIVE EXAMPLES

An aqueous coating composition was prepared for control. The aqueouslatex was separately mixed with the aqueous dispersion of nanosilica inparts by weight shown in Table 1 below to form an aqueous coatingcomposition for control as an aqueous blocking agent. ComparativeExample A used R-9029 from DSM, which is an aqueous polyurethanedispersion having a pH of 7.2-8.5; Comparative Example B used AC-122,which is an aqueous acrylics dispersion with a pH of 8.5; ComparativeExample C used CUR995, which is an aqueous polyurethane dispersion witha pH of 7-8.

Then, above various aqueous sealing agents were sprayed on the treatedsamples, and dried in air for 15 minutes, in an oven at 40° C. for 1hour, then cooled in air for 30 minutes. The obtained samples werepolished by using 3MT Wetordry™ Sheet 240 sandpaper. Next, the acrylicvarnish 481C54086K supplied by Valspar was sprayed twice, and after eachcoating, the sample was air-dried for 10 minutes, in an oven at 40° C.for 1 hour, then taken out of the oven, and kept at room temperature for48 hours. Then, the effect of the grain puffing was measured by anoptical microscope.

Example 1

The aqueous coating composition of the present invention was formulatedas below. The aqueous acrylics latex DSM XK-102 from DSM was mixed withthe aqueous dispersion of nanosilica in parts by weight as shown inTable 1 below to form the aqueous coating composition of the presentinvention. The aqueous acrylics latex DSM XK-102 used in the presentinvention is an anionic aqueous latex having an anionic hydrophilicgroup in a molecular chain and has a pH of 6.2 to 6.8.

The aqueous coating composition of the present invention was thensprayed onto the treated sample and dried in air for 15 minutes, in anoven at 40° C. for 1 hour, then cooled in air for 30 minutes. Theobtained samples were polished by using 3MT Wetordry™ Sheet 240Sandpaper. Next, the acrylic varnish 481C54086K supplied by Valspar wassprayed twice, and after each coating, the sample was air-dried for 10minutes, in an oven at 40° C. for 1 hour, then taken out of the oven,and kept at room temperature for 48 hours. The effect of the grainpuffing was then measured using an optical microscope.

Table 1 below summarizes the composition and the grain puffing effect ofthe aqueous coating composition of the present invention and the aqueousblocking agents used for the control.

TABLE 1 Ex1 CExA CExB CExC DSM XK-102 83% DSM R-9029 83% AC-122 83%CUR995 83% WV 33 WB Ludox 10% 10% 10% 10% Additional additives  7%  7% 7%  7% Total 100%  100%  100%  100%  Grain puffing NO Slight slightmedium

It can be seen from the visual results that the anionic aqueous latexhaving a lower pH (such as XK-102) is a key factor for achieving ananti-grain-puffing effect. In contrast, those aqueous sealing agentsformed by using other aqueous latice having a pH greater than 7.0 havean unanticipated effect.

Surface Roughness

In order to further verify the anti-grain-puffing effect of the aqueouscoating composition of the present invention, the aqueous coatingcomposition of Example 1 of the present invention and the conventionalaqueous sealing agent WTD7500 containing an anionic aqueous latex havinga pH greater than 7.0 were respectively formed into ananti-grain-puffing coating, which were applied in the same manner as inthe above Example 1 to form a sample to be tested.

The surface of the sample was imaged in a dark field mode by an opticalmicroscope. The microscope used was a Keyence VHX-5000 with a Z1000lens. The roughness parameters defined by ISO Standard 25178 werecalculated from the height distribution in a small area of size 5 mm*5mm and averaged. Before calculating the surface roughness, the slope andshape of the image were calibrate by fitting a 2-level polynomial.

The results of surface roughness were shown in FIGS. 1 and 2 .

It can be seen from the results of the surface roughness that thearticles of the present invention have significantly lower surfaceroughness (up to 5.4 microns), compared to the comparative sample withan anionic aqueous latex having a pH of more than 7.0 as ananti-grain-puffing coating with a surface roughness of up to 8.0microns.

Although the present invention has been described with reference tonumerous embodiments and examples, those of ordinary skill in the artwill recognize from the present invention that other embodiments can bedevised without departing from the scope and spirit of the invention.

What is claimed is:
 1. An aqueous coating composition for forming ananti-grain-puffing coating on a wood substrate, comprising: (a) anaqueous dispersion of polymeric particles, wherein the polymericparticles comprise polymer having an anionic hydrophilic group on itsmolecule chain, and the aqueous dispersion of polymeric particles has apH of less than 7.0; and (b) an aqueous dispersion of nano-silica. 2.The aqueous coating composition of claim 1, wherein the aqueousdispersion of polymeric particles has a pH of more than 5.0.
 3. Theaqueous coating composition of claim 1, wherein the aqueous dispersionof polymeric particles has a pH of more than 6.0.
 4. The aqueous coatingcomposition of claim 1, wherein the anionic hydrophilic group isselected from a carboxylic acid group, a sulfonic acid group, aphosphonic acid group, a phosphonite group, a phosphoric acid group andthe combination thereof.
 5. The aqueous coating composition of claim 1,wherein the aqueous dispersion of polymeric particles has a hydroxylvalue of 0-100 mg KOH/g, preferably 20-80 mg KOH/g.
 6. The aqueouscoating composition of claim 1, wherein the polymer particles have aparticle size of less than 100 nm.
 7. The aqueous coating composition ofclaim 1, wherein the aqueous dispersion of polymeric particles comprisesan aqueous dispersion of silicone, an aqueous dispersion ofstyrene-acrylate, an aqueous dispersion of acrylates, an aqueousdispersion of silicone modified acrylate, an aqueous dispersion of vinylacetate, an aqueous dispersion of vinyl acetate-acrylates, an aqueousdispersion of vinyl acetate-ethylene, an aqueous dispersion ofethylene-vinyl acetate, an aqueous dispersion of vinylacetate-acrylates-ester of versatic acid or any combination thereof. 8.The aqueous coating composition of claim 7, wherein the aqueousdispersion of polymeric particles has a solid content of 30-50%.
 9. Theaqueous coating composition of claim 1, wherein the nano-silica has aparticle size in the range of 5-100 nm.
 10. The aqueous coatingcomposition of claim 1 comprising, based on the total weight of theaqueous coating composition, 70-90 wt % of the aqueous dispersion ofpolymeric particles; 0.1-10 wt % of the aqueous dispersion ofnano-silica; and 0-29.9 wt % of additional additives.
 11. The aqueouscoating composition of claim 1, wherein the coating composition is aprimer for a wood substrate.
 12. A two-part aqueous primer for formingan anti-grain-puffing coating on a wood substrate, comprising (a) anaqueous coating composition, comprising: (i) an aqueous dispersion ofpolymeric particles, wherein the polymeric particles comprise polymerhaving an anionic hydrophilic group on its molecule chain, and theaqueous dispersion of polymeric particles has a pH of less than 7.0; and(ii) an aqueous dispersion of nano-silica; and (b) a blocked isocyanate.13. The two-part aqueous primer of claim 12, wherein the blockedisocyanate is selected from the group consisting of a blocked aliphaticpolyisocyanate, a blocked cycloaliphataic polyisocyanate, a blockedaromatic polyisocyanate and the combination thereof.
 14. An article,comprising (a) a wood substrate having at least one major surface; (b)an anti-grain-puffing coating directly applied on the major surface ofthe wood substrate, formed from the aqueous coating compositioncomprising: (a) an aqueous dispersion of polymeric particles, whereinthe polymeric particles comprise polymer having an anionic hydrophilicgroup on its molecule chain, and the aqueous dispersion of polymericparticles has a pH of less than 7.0; and (b) an aqueous dispersion ofnano-silica; and (c) a coating applied on the anti-grain-puffingcoating, formed from an aqueous coating composition.
 15. (canceled) 16.(canceled)
 17. (canceled)